Insulated terminal and die for making same



March 29, 1960 E. FLOYD, JR 2,930,836

INSULATD TERMINAL AND DIE FOR MAKING SAME Filed Sept. 23, 1955 l 2 Sheets-Sheet l l Ill/11111 111111111111111 March 29, 1960 E. FLOYD, JR

INSULATED TERMINAL AND DIE FOR MAKING SAME Filed Sept. 23, 1955 2 Sheets-Sheet 2 INVENTOR. dwin floyd, zfr. BY

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Unitey States Patent O INSULATED TERMINAL AND DIE FOR MAKING SAME Edwin Floyd, Jr., Harrisburg, Pa., assignor to AMP Incorporated, Harrisburg, Pa.

Application September 23, 1955, Serial No. 536,127

3 Claims. (Cl. 174-84) An electrical circuit is no better than its most vulnerable part. Like any other transmitting means, a iiaw in one section will reduce the eiciency of the entire component to the level of the imperfect part. Thus, when engineering a complex guided missle, rocket, airplane, or artificial astral body, etc., the circuit supplying the current to the components is the arterial network supplying the lifes blood to the system. The junctions of these current-ladened conductors are indeed vulnerable areasof the device. A suitable connection, performance-wise, must be secure to a degree that will withstand the extreme vibrations typically present in devices of the class described. In addition the connection must be highly conductive, approaching the conductivity of the conductor as a desideratum. In addition it is often necessary to'provide an insulation for the connection. Properties of lthe insulation include high heat resistance, durability, inertness to a variety of chemicals and solvents with which it may come into contact, and, of course, good dielectric properties. From a manufacturing standpoint, the connector should be easily applied and inexpensive to manufacture.

With these factors in mind, it is an object of this invention to provide a connection that will combine to the maximum the features set forth above with special emphasis on the ability of the insulation to withstand high temperatures. Using the insulated connector set forth in this application it is possible to provide an insulation that will withstand greater temperatures than the conductor itself.

It is also an object of this invention to provide a connector capable of being insulated with ceramic or glass as well as other types of standard insulating sleeves.

It is a further object of this invention to provide a means crimping a connector onto a conductor in such a manner as to make a secure efficient connection and at the same time provide a means for ing sleeve thereto.

Another object of this invention is to provide a set of dies that will crimp a connector onto a conductor in such a manner that a strong, eiricient connection is made as well as providing a lock means for securing an insulating sleeve tothe connection. l

Other important features andobjects of the invention to'v which reference has not been made hereinabove will appear hereinafter when the following description and claims are considered with the accompanying drawings, inwhich:

rFigure 1 is an exploded view of an improved connector embodying principles of this invention;

Figure 2 is a perspective view of the improved connector prior to securing a conductor;

Figure 3 is a perspective view of the connector of Figures 1 and 2, withY a conductor cold forged thereto, showing the insulating sleeve in `a retracted position;

lFigure 4 is a plan view of the improved connector with a conductor secured in place;

securing an insulat- Figure Sis a sectional view taken through plane V-V of Figure 4;

Figure 6 is a sectional view taken through plane VI-VI of Figure 5;

Figure 7 is a side view of the connector shown in Figures 1-6, with a conductor secured in place and the insulating sleeve partially retracted; v

Figure 8 is a sectional view taken through plane VIII-VIII of Figure 7;

Figure 9 shows a connector illustrative of the invention, particularly adaptable to securing two wires together;

Figure 10 is a view of the connector shown in Figure 9 with the insulation sleeve retracted, demonstrating how the connector is applied to the wires;

Figure 11 is a diagrammatic view, showing the rela-- tionship of parts between the connector, the conductor and the crimping dies;

Figure 12 is a perspective view of the crimping dies;

Figure 13 is an end view of the crimping dies; and

Figures 14 and 15 show other modifications of connectors incorporating principles of the invention having different means for locking the sleeve in place.

As shown in Figure 1, the preferred embodiment of the improved, insulated connector is made in threeV pieces. A tongue member 10 has an opening 12 for securing the tongue -to a binding post to permit transference of electricity. A ferrule 14 forming one end of tongue 10 is member 18 surrounds the assembly.

, member 18 is tubular and may be made from ceramic intermediate sleeve 16 but permits the insulating sleeve to move longitudinally relative to the intermediate sleeve. A pair of slots 22, 22 are provided at diametric positions on ange 20 for reasons to be discussed later.

.The conductor C is secured to the connector by crimping the intermediate sleeve to the conductor by use of a pair of crimping dies as shown in Figures 12 and 13.

The particular dies shown in the drawings are comprised of a pair of V-shaped members 30, 30 which constitute an upper and lower die means respectively. Extending outwardly from each of the free ends of lthe V is a at surface 32. The at surfaces 32 of one die oppose the surfaces 32 on the other die as shown in Figure 12. One of the die means iits inside the other and abutments 34 prevent opposed surfaces 32 from contacting each other when the dies are closed. Thus when the dies are closed on a connector with a conductorlocated therein, the connector and conductor are deformed into the shape of a square, as seen in cross section (see Figures 8 and 11), with a pair of lugs 36, 36 extending from opposite sides of the connector. f

As vshown in the drawings, two sets of dies are provided. One set acts to crimp the connector to the con-l ductor, whereas the second set crimps the connectonto the insulation sheath covering the conductor. Spacer plates 36 are provided between each set of dies. Howin two longitudinal sections.

plates. other, as shown in Figure 12. Screws 42 extend through the assembly to secure the dies and plates in their -respe-. tive operative positions.

` oneness kWhen applying the connector to the conductor C the insulation sheath is stripped from one end of the conductor to expose a bare portion of the conductor. The connector is assembled as shown in Figure 2, with ferrule 14 within sleeve 16 and insulating member 1S surrounding sleeve 16. Flanges 19, 19 on each end of sleeve 16 limit the travel of the insulating `member 18 relative to sleeve 16 between the position shown in Figure 2 and the position shown in Figure 8.

With the assembly in the position shown in Figure 2 the conductor C is inserted within sleeve 16. The bare end of the conductor will extend through ferrule 14 and the insulation will abut against the rear end of the ferrule (see Figure thus acting as a positioning means. When the bare end of the conductor extends part way through ferrule 14, the operator can 4be assured that the conductor and ferrule are in proper position.

When the conductor is positioned within the ferrule, the crimping dies are applied across the sleeve thereby crimping the ferrule onto the bare end of the connector and the sleeve onto the Iinsulation (see (Figure 5). As shown in Figure l1 the connector and conductor are deformed from the dotted line position to the full line position. A pair of lugs 36, 36 are thus formed on sleeve 16 in a position whereby they mate with slots 22 in ange 2t).

After the connector is crimped to the conductor, as shown in Figure 3, insulating sleeve 18 is movedv forwardly relative to sieeve 16, lugs 36 engaging slots 22. The iange 1g on sleeve 16 limits forward travel of the insulating sleeve. In this position sleeve 16 is wholly within insulating member 18 and the two are free to rotate relative to each other `since lugs 36110 longer engage slots 22.

The sleeve 16 is then rotated relative to insulating member 1S so that lugs 36' are no longer aligned with slots 22. This in effect serves to lock member 18 in place relative to sleeve 16. A bayonet type connection may be provided to prevent inadvertent unlkin-g of these members.

The insulating member 13 may be subsequently disengaged from sleeve 16 by realigning lugs 36 4with slots 22 again permitting relative longitudinal movement. However accidental realignment is prevented by frictional contact between ridge 19 and the front edge of the insulating member.

The modification shown in :Figure 15 provides an addi tional means of preventing accidental relative rotation ofv insulating member 18 and sleeve 16 through the medium of tabs 44 which are cut from ridge 29. These tabs are `bent inwardly to engage recesses 46 in the one end of the insulating member. Thus the frictional engagement between tabs 44 and recesses ai6 tends to prevent relative rotation therebetween. Also the inner cross sectional conguration of the insulating sleeve may be slightly elliptical with the maior axis extending along the plane of slots 22. When sleeve 16 is rotated to a locking position, i.e.: 90 vfrom the position shown in Figure 5',

lugs 20 are wedged within the insulating sleeve along the minor axis of the ellipse. This provides a tight frictional engagement between the lugs and the inner surface of the insulating sleeve.

Figures 9 and l() show a butt connector used for splicing two or more wires together in an end to end engagement which embodies principles of the invention.

An inner metal ferrule 6i) is open at each end. A metal sleeve 62 is secured to the ferrule so that the ferrule is located centrally within the seeve. The ferrule and sleeve have a central opening to permit inspection. The edge of the opening in the sleeve is turned inwardly to secure 'the ferrule in place. Furthermore the opening in the sleeve operates as a reference point in determining where the crirnps shouldbe made.

An outside insulating member 64 surrounds sleeve 62 and! is relatively slid'able thereto. A ilange 66 extends in- `vided at diametnical positions on the flange.

wardly from insulating member d4. This tiange may be integral with the insulating member or formed as a separate member which is secured in place Within the insulating member. fFlange 66 has the same cross-sectional configuration as ange 2i) set -forth in the embodiment of lFigures 1-3, i.e.: the circumference of the opening in the flange is slightly greater than the outside circumference of sleeve 62, and a pair vof slots are pro- The sleeve 62 is flared outwardly at each end as at 66 to permit it to telescope relative to the insulating member but prevent disengagement of the two members.

The method of applying the butt connector to the conductors is similar to the method of applying the connector thus assuring proper positioning of the conductor prior to f crimping. With the conductor properly in place, crimping dies of the type shown in Figures l2 and 13 are brought to bear upon sleeve 62. The dies designated A defortn the sleeve and ferrule onto the conductor. The dies designated B crimp sleeve 62 onto the insulation. The particular crimp employed forms lugs on the sleeve vwhich mate with the slots formed in ange 66. After the v crimp is effected, sleeve 62 is telescoped back onto insulation mem-ber 64 and rotated into locking position in the same manner as employed in the case of the connector of Figures 1-3.

The embodiment set forth in Figure 14 is similar to that shown in FiguresV l-S. However the connector shown inl Figure 14 has an inner metallic sleeve 70, bonded to an insulating member 74. One end of this sleeve is formed in a shape similar to the shape of the cross section ofthe crimp, as at 72. This serves the same purpose as ridge 20 with slots 22 of Figures l-3. After a conductor is crimped onto a ferrule and protruding lups are formed dametrically thereon, the connector is inserted into the insulating member by aligning the ferrule with the end of sleeve 72. After the ferrule is within the sleeve, it is rotated out of alignment, thus preventing disengagement.

l't is noted that the outer layer of'insulation may be applied by coating a metal sleeve with a glaze, such as used the scope ofA the-invention. The matter set forth in the foregoing description and accompanying drawings is ottered by way of illustration only. The actual scope of the invention is intended to be deiined in the following claims when viewed in their proper perspective against the prior art.

lclaim:

l. An insulated electrical connector adapted to bel cold-forged onto a conductor including: a ferrule crimped onto a conductor so as to form a plurality of lugs extending longitudinally of the ferrule and on the exterior ofthe ferrule, an insulation sleeve slidably surrounding the ferrule, an inner flange on the sleeve, and a plurality-of slots in the ange, disposed to receive the lugs on the ferrule, whereby the insulating sleeve maybe releasably locked onto the ferrule by sliding the sleeve over the ferrule when the lugs engage the slots and then rotating the sleeve relative to the ferrule.

2. An insulated connector for securing electrical transmission elements including: an electrical conductor, a metallic casing surrounding said conductor and secured thereto, said casing having a pair of longitudinally extending lugs protruding therefrom, a rigid insulation sleeve, an inwardly extending flange on one end of the sleeve, and a pair of slots positioned on the sleeve and adapted to mate with the lugs on the casing, whereby the insulating sleeve may be tted over the casing when the lugs cooperate with the slots and releasably locked in place by partial rotation of the sleeve.

3. An insulated connector capable of connecting a plurality of electrical conductors so as to withstand high temperatures comprising: a metal ferrule deformed onto the conductor to form part of a longitudinally extending locking means, an insulation sleeve surrounding the ferrule and having longitudinally extending means on its interior which is complementary with the locking means on the ferrule to releasably lock the sleeve to the ferrule, and one end ofthe ferrule being adapted to receive a con- References Cited in the file of this patent UNITED STATES PATENTS 663,490 Cleveland Dec. 1l, 1900 2,316,267 McLarn Apr. 13, 1943 2,567,155 Macy Sept. 4, 1951 2,589,368 Graham et al Mar. 18, 1952 2,603,679 Pavlinetz July 15, 1952 2,612,932 Vinson Oct. 7, 1952 2,622,314 Bergan Dec. 23, 1952 2,654,873 Swengel Oct. 6, 1953 2,729,695 Y Pierce Jan. 3, 1956 2,817,698 Schneiderman Dec. 24, 1957 

